Method and apparatus for fabricating contoured laminate structures

Abstract

Apparatus for forming composite plies on a contoured tool includes a forming head for forming the composite plies on the tool. The forming head is mounted on a manipulator and includes a compliant nosepiece adapted to conform to the contoured tool.

What is claimed is: 
     
       1. An apparatus for forming composite plies on a contoured tool, comprising:
 a manipulator; 
 a forming head mounted on the manipulator for forming the composite plies on the contoured tool, the forming head comprising:
 a flexible track comprising a plurality of spaced apart segments that are spaced apart along the flexible track, permitting the flexible track to flex as required to conform to the contoured tool; 
 a unitary compliant nosepiece extending along a length of the flexible track with portions of the unitary compliant nosepiece being removably mounted in each of the plurality of spaced apart segments, wherein the unitary compliant nosepiece is adapted to conform to the contoured tool and to contact and sweep laminate plies over the contoured tool along at least two axes of movement of the forming head; and 
 a plurality of actuators coupled with the unitary compliant nosepiece, wherein the plurality of actuators is respectively configured to locally displace corresponding sections of the unitary compliant nosepiece; and 
 
 a controller configured:
 to learn a geometry of the contoured tool by encoding force feedback received when the unitary compliant nosepiece is brought into contact with the contoured tool; and 
 based on the encoded force feedback, to adjust the plurality of actuators to a configuration that substantially matches the unitary compliant nosepiece to local contours of the contoured tool. 
 
 
     
     
       2. The apparatus of  claim 1  further comprising an articulated arm robot. 
     
     
       3. The apparatus of  claim 1 , wherein the forming head further includes:
 a support bracket coupled with the manipulator; and 
 wherein the unitary compliant nosepiece and the plurality of actuators are carried on the support bracket. 
 
     
     
       4. The apparatus of  claim 3 , wherein:
 each of the plurality of actuators is a pneumatic cylinder having an actuator rod; and 
 each actuator rod is connected with the flexible track. 
 
     
     
       5. The apparatus of  claim 1 , wherein the forming head further includes:
 a groove in the flexible track, wherein the unitary compliant nosepiece is removably mounted in the groove. 
 
     
     
       6. The apparatus of  claim 1 , further comprising:
 a plurality of track holders swivel mounted on the forming head and linearly displaceable relative to the manipulator, wherein the flexible track is removably held in the plurality of track holders. 
 
     
     
       7. An end effector for forming composite plies on a contoured tool comprising:
 a unitary compliant nosepiece configured to contact and sweep the composite plies onto the contoured tool along at least two axes of movement of the end effector; 
 a flexible track comprising a plurality of spaced apart segments in which portions of the unitary compliant nosepiece are removably mounted, wherein the unitary compliant nosepiece extends along a length of the flexible track, wherein the plurality of spaced apart segments is spaced apart along the flexible track, permitting the flexible track to flex as required to conform to the contoured tool; 
 a plurality of actuators for applying force to the unitary compliant nosepiece; and 
 a controller configured:
 to learn a geometry of the contoured tool by encoding force feedback received when the unitary compliant nosepiece is brought into contact with the contoured tool; and 
 based on the encoded force feedback, to adjust the plurality of actuators to a configuration that substantially matches the unitary compliant nosepiece to local contours of the contoured tool. 
 
 
     
     
       8. The end effector of  claim 7 , wherein the actuators are coupled with the flexible track and are respectively configured to locally displace corresponding sections of the unitary compliant nosepiece. 
     
     
       9. The end effector of  claim 7 , further comprising:
 a bracket adapted to be coupled with a manipulator; and 
 a mounting block attached to the bracket, wherein the actuators are mounted on the mounting block. 
 
     
     
       10. The end effector of  claim 7 , further comprising:
 a plurality of track holders respectively coupled with the actuators for holding the flexible track. 
 
     
     
       11. The end effector of  claim 10 , wherein the track holders are pivotally connected with the actuators. 
     
     
       12. The end effector of  claim 10 , wherein:
 each of the actuators includes a displaceable actuator rod, wherein the track holders are respectively attached to the displaceable actuator rods. 
 
     
     
       13. The end effector of  claim 7 , wherein the actuators are arranged in an arc generally matching a contour of the contoured tool. 
     
     
       14. The end effector of  claim 7 , further comprising:
 a groove in the flexible track, wherein the unitary compliant nosepiece is removably mounted in the groove. 
 
     
     
       15. The end effector of  claim 7 , further comprising:
 a plurality of track holders swivel mounted on the end effector and linearly displaceable relative to the end effector, wherein the flexible track is removably held in the plurality of track holders. 
 
     
     
       16. A method of forming a composite ply on a contoured tool, comprising:
 mounting a forming head on an automatically controlled manipulator, the forming head comprising a flexible track comprising a plurality of spaced apart segments that are spaced apart along the flexible track, permitting the flexible track to flex as required to conform to the contoured tool; 
 removably mounting portions of a unitary compliant nosepiece in each of the plurality of spaced apart segments such that the unitary compliant nosepiece extends along a length of the flexible track; 
 bringing the forming head into contact with the contoured tool; 
 encoding force feedback received when the unitary compliant nosepiece is brought into contact with the contoured tool to learn a geometry of the contoured tool; 
 based on the encoded force feedback, adjusting a plurality of actuators to a configuration that substantially matches the unitary compliant nosepiece to local contours of the contoured tool, wherein the plurality of actuators is coupled with the unitary compliant nosepiece and is respectively configured to locally displace corresponding sections of the unitary compliant nosepiece; 
 forming the composite ply onto the contoured tool at each of the sections along the contoured tool, including using the automatically controlled manipulator to apply a pressure to the composite ply with the unitary compliant nosepiece and to sweep laminate plies over the contoured tool along at least two axes of movement of the forming head. 
 
     
     
       17. The method of  claim 16 , wherein moving the forming head is performed by the automatically controlled manipulator. 
     
     
       18. The method of  claim 16 , wherein moving the forming head is performed using a robotic arm. 
     
     
       19. The method of  claim 18 , wherein forming the composite ply on the contoured tool includes using the robotic arm to apply a pressure to the forming head. 
     
     
       20. The method of  claim 16 , wherein forming the composite ply on the contoured tool includes configuring a forming member to substantially match contours of the contoured tool, including using the plurality of actuators to configure the forming member. 
     
     
       21. A method of forming a composite ply on a contoured tool, comprising:
 bringing a forming head into proximity with a location on the contoured tool, including moving the forming head using a robotic arm, wherein the forming head comprises a flexible track comprising a plurality of spaced apart segments in which portions of a unitary compliant nosepiece are removably mounted; 
 configuring the unitary compliant nosepiece on the forming head to substantially match a contour on the contoured tool, including:
 bringing the forming head into contact with the contoured tool; 
 encoding force feedback received when the unitary compliant nosepiece is brought into contact with the contoured tool to learn a geometry of the contoured tool; 
 adjusting a plurality of actuators based on the encoded force feedback to a configuration that substantially matches the unitary compliant nosepiece to local contours of the contoured tool, wherein the plurality of actuators is coupled with the unitary compliant nosepiece and is respectively configured to locally displace corresponding sections of the unitary compliant nosepiece; 
 
 positioning a ply adjacent the contoured tool; 
 bringing the unitary compliant nosepiece into contact with the ply; 
 moving the unitary compliant nosepiece over the contoured tool using the robotic arm along at least two axes of movement of the forming head; and 
 applying pressure to the composite ply using the robotic arm during moving the unitary compliant nosepiece over the contoured tool to sweep laminate plies over the contoured tool along at least two axes of movement of the forming head. 
 
     
     
       22. The method of  claim 21 , further comprising:
 applying pressure to the ply using the actuators.